Unit - I CHAPTER - i DESIGN OF MACHINE TOOL GEARBOX Syllabus : Introduction to machine tool gearboxes, design and its applications, Basic considerations in design of drives, Determination of variable speed range, Graphical representation of speed and structure diagram, Ray diagram, Selection of optimum ray diagram, Deviation diagram, Difference between numbers of teeth of successive gears in a change gear box. Section No. Topic Name 1.1 Introduction L. 1.2 Multi-Speed Gear Box in Machine Toois 1-3 1.3 Stepped Regulation of Speed in Multi-speed Gear Box 1-5 14 Selection of Geometric Progression Ratio (9) in Multi-speed 1-24 Gearbox 15 Parameters in Kinematic Design of Multispeed Gearbox 1-31 1.6 Kinematic Diagram of Gearbox (Gearing Diagram) 1-35 17 _t Structurai Formulae 1-35 1.8 Structure Diagram 1-39 1.9 Selection of Optimum Structure Diagram 1-45 1.10 Ray Diagram and Speed Diagram 1-47 1.14 General Guidelines for Gearbox Layout 1-52 1.12 | Solved Examples 1-57 K 1.13 Compound Gearbox 1 - 148 1.14 __| University Questions with Answers 156 1-4 Mechanical System DesignDesign of Machine Tool Gearbox 1.1 introduction © Gearbox is 2 mechanical device which is used for transmitting motion or power from the prime mover to the machine by changing the speed or torque or by changing the orientation of drive. Refer Fig. 1.1 + Gearbox consists of number of gear pairs which may be of same or different re Prime Machine mover tool rrr roterrere Fig. LI: Gearbox 1.1.1 Purpose of Gearnox 6 [ SPPU : Dec. 2014 ] * In almost all the engineering applications when prime-mover drives the machine for specitic output, gearbox is required to serve one or more of the following purposes : i) To reduce the speed or to increase the torque ¢ When the torque required by the driven machine is more than the torque developed by the prime-mover, the gearbox is used to increase the torque. * To increase the torque gearbox reduces the speed between the driving and driven shaft. ii) To convert standard input speed into the specific output speed © In some applications prime-mover runs at a standard speed and machine runs at a specific speed or it runs between specific speed range. * In such cases, gearbox is used to convert standard speed of prime-mover into the specific speed or specific speed range of the driven machine. iii) To convert single speed of prime-mover into multiple output speeds © For machine tools like lathe, milling, drilling, etc. the prime-mover (motor) runs at a single speed but it is required to run the machine at different speeds for different operations. © For such cases, the gearbox is used to convert the single input speed into the multiple output speeds. iv) To increase the speed or to reduce the torque * In some industrial applications, the machine tool runs at higher speed than the prime-mover speed. + In sucn cases, ine gearbox increases the speed irom the prime-mover shaft to the machine tool shaft. Mechanical System DesignEE ——————————————————— Design of Machine Too! Gearbox ¥) To provide specific relative position of prime-mover and machine tool shaft « incertain applications specific relative position of prime-mover shaft and machine tool shaft is required. In that case, the gearbox is used to connect those two shafts. 1.1.2 Types of Gear Boxes © Gear boxes are classified on the basis of different criterion. The classification of gear boxes is as follows : «According to the relative position of the input and output shafis i) Paraliel axes gear boxes ii) Co-axial gear boxes iii) Intersecting axes gear boxes iv) Non-intersecting and perpendicuiar axes gear boxes According to the number of stages i) Single stage gear box ii) Multi-stage gear box « According to the number of speed ratios i) Singie speed gear box if) Muiti-specd gear box Single speed gear box ‘© These type of gear boxes operate with only one speed ratio (gear ratio). © In this type of gear box, for every input speed, there is only one output speed. Multi-speed gear box © These type of gear boxes operate with more than one speed ratio (gear ratio). «In this type of gear box, for every input speed there are more than one output speeds. For example : Automobile gear boxes, machine tool gear boxes, etc. Following are the three types of multi-speed gear box : i) Constant mesh gear box ii) Sliding mesh gear box iii) Synchromesh gear box 4.2 Multi-Speed Gear Box in Machine Tools In each machine tool number of operations are carried out. For example : In lathe machine turning, drilling, threading, parting, etc. are to be carried out on a workpiece. 4-3 Mechanical System DesignDesign of Machine Tool Gearbox * For optimising the tool life and minimising the cost of machining, each machining operation is carried out at a specific cutting speed. Hence, different machining operations need different spindle speeds. + We know that, the cutting speed for any machining operation is given by, V = mDn (LL) Where , V = Cutting speed in m/min. D_ = Diameter of workpiece during the cutting in m n = Spindle speed in rpm. + From the above equation (1.1), the spindle speed is given by, _ n= 35 a (1.2) + From the above equation (1.2), it is clear that, if machine tool performs only one type of operation then also the required spindle speeds are different for-different workpiece diameters. * Therefore, the machine tools require to operate with different spindle speeds but the prime-mover iike electric motor operates at a constant (single) speed. * It means, to obtain number of output speeds from single input speed, the multi-speed gear box is required in machine tools. if 1.2.1 Basic Considerations in Design of Multi-speed Gear Box 0 [ SPPU : May 2015 ] ‘The basic considerations in the design of multi-speed gear box are as follows : i) Optimum number of speed steps : The total speed range of multi-speed drive should be divided into optimum number of speed steps with increment of 10 to 20 %. ii) Change of speed without stopping the electric motor : In case of multi-speed rive all the speed steps should be obtained without stopping or disturbing the electric motor. ii) Obtain desired speed change without passing through intermediate specd steps : The multi-speed drive should provide ‘the required change in speed without passing through all the intermediate speed steps. iv) At one time only one set of gears in engagement : In multi-speed drive, at one time only one set of gears should be engaged to obtain the desired speed. v) Use minimum number of parts : The multi-speed drive should contain minimum possible number of parts like gears, shafts, bearings, etc. vi) Ergonomically designed control unit : Te control unit of multi-speed drive should be designed ergonomicatly and it should be located centrally. It should be easy to operate and convenient to the operator. 1-4 Mecnanical System Design i | aDesign of Machine Tool Gearbox vii) Drive unit located inside the machine tool : All the components of the multi-speed drive should be located inside the machine tool. 4.3 Stepped Regulation of Speed in Multi-speed Gear Box © In case of multi-speed gear box, for a single input speed, the output speed is obtained between maximum speed (Max) and minimum speed (min) © The variation of the output speed is not stepless but it is in the discrete steps. Laws for Stepped Regulation s@ [ SPPU : May 2011, Dec. 2011, May 2013, May 2014 } © Ideally multi-speed drive gives stepless variation which can be obtained by hydraulic, electrical or friction devices. © Ina stepped regulation of speed, only certain discrete values of spindle speeds are available. Hence, to select the discrete steps of speed between two extreme values (imax aNd Nain) the following three laws are used : 1. Speed steps based in arithmetic progression 2. Speed steps based in harmonic progression 3. Speed steps based in geometric progression 1, Speed steps based on arithmatic progression In this law of progression, the difference between any two successive spindle speeds is constant. ° Let, Sax and Nig = Maximum and minimum spindle speed in rpm ny, Np.....n, = Different spindle speeds in rpm z = Total number of speed steps a, = Difference of the arithmatic progression in rpm (13) © Hence, the different spindle speeds are, A) = Onin Ny = my tay = Amin + ae ng = mo + ay =(Mmin + at) +e = Min + 244 ng = 13444 = (Min + 2a) +8y = Amin + 3a 1-5 Mechanical System DesignDesign of Machine Tool Gearbox ny = mat ay = min +(Z—1) ay * Cutting speed for machining operation is, V = xDn, m/min v D= a o (14) Where, D = Diameter of workpiece during the cutting in m n = Spindle speed in rpm V = Cutting speed in m/min. © For maximum cutting speed 'V’ under the particular machining condition, the diameter range of workpiece that can be machined at a particular spindle speed ‘ny! is, a. . v Upper limit of diameter i.e. Do = rn a 5 ; Vv Lower limit of diameter i.e. Den = TMK Range of diameters is, SD, = Dy -Dust 8D, = orate t{t- i } «- (15) mh My For example : Consider a multi-speed drive having following specifications : Maximum spindle speed (nax) = 500 rpm Minimum spindle speed (Myyin) = 60 rpm Number of speed steps (2) = 12 Cutting speed (V) = 25 m/min 0 For the above data, the different parameters based on the arithmatic progression are calculated as follows : i) Common difference of arithmatic progression : _ 500 ~ 60 (12-1) ay = a = 1-6 Mechanical System Designii) Spindle speeds : ny m2 n3 ny Ns Ng Re ng Ng Tio my ny Design of Machine Tool Gearbox Dyin = 60 rpm ny + ay = 60 + 40 = 100 rpm ng +a, = 100 + 40 = 140 rpm ny +a, = 140 + 40 = 180 rpm ng +a, = 180 + 40 = 220 rpm ns +a, = 220 + 40 = 260 rpm = ng +a; = 260 + 40 = 300 rpm ny +a, = 300 + 40 = 340 rpm ng + a; = 340 + 40 = 380 rpm No + ay = 380 + 40 = 420 rpm nyo + ay = 420 + 40 = 460 rpm = Mag = Nyy + @y =.460 + 40 = 500 rpm iii) Successive speed ratio : o 2 $3 oa 6 or B= eg = 167 calm 1.2857 7 -2. 1.222 fe = 38 = 11818 fe = 30 = 1.1538 Se OO 1.133 Be asp n hiT6 Mechanical System Designou Design of Machine Too! Gearbox Nig _ 420 _ iv) Upper limit of diameter of workpiece : Dye = Dd D2 D3 Dg Ds De Dy Dg Do i} Fe = Fay = 11082 Bu _ 460 _ mit = Fp 7 10982 Biz __ 500 _ ia = eg 7 1.9869 V_ 25 _ 7.9577 _ 7957.747 Vv 25 _ 79577 MT mam any Why nk "k 1957-747 _ 7957-747 _ 139 6991 mm a 60 T9ST.747 _ 7957-7487 «99 5974 mom ng 1 FOSTTAT | TOSTTAT © s6-8411 mam in 140 1957.747 _ 7957-747 _ 44.097 mm zu 180 7957.747 _ 7957.747 ee Oe = 36.1715 mm 7957.747 _ 7957-747 _ 39.6067 mm aa 260 7957-147 _ 7957.747 _ SLIT OT = 26.5258 mm 7957.74 _ 7957.747 _ ee Og = 234051 mm 7957.747 _ 7957.747 _ DSLINT . PSTIAT — 59.0414 mm 7957-747 _ 7957.47 _ Ue, OD = 18947 mm 957.747 _ 7957.747 _ cee Oe = 17.2894 mm 7957. : T9ST.IAT _ 7957-7487 15 9154 mm na 500 1-8 Mechanical System Design| v) Range of diameters BD = (Ox ~Dyst) mm 8D, = D,-Dz 8D) = D2- Design of Machine Tool Gearbox 132.6291 — 79.5774 = 53.0517 mm = 79.5774 — 56.8411 = 22.7363 mm §D3 = D3 -D, = 56.8411— 44.2097 = 12.6314 mm 8D, = Dg -Ds = 44,2097 ~36.1715 = 8.0382 mm SDs = Ds —Dg = 36.1715 ~30.6067 = 5.5648 mm 8Dg = Dg —D7 = 30.6067 — 26.5258 = 4.0809 mm 8D, = Dz —Dg = 26.5258-23.4051 = 3.1207 mm BDz = Dg —Do = 23.4051 20.9414 = 2.4637 mm 5Dy = Do —Djo = 20.9414-18.947 = 1.9944 mm Dio = Di 19 ~ Dy = 18.947 —17.2994 = 1.6476 mm BDy) = Dy, —Dyz =17.2994~-15.9154 = 1.384 mm vi) Parameter summary : All of. the above calculated parameters are summarised in the following Table 1.1 : Table 1.1 : Range of diameters for different spindle speeds in arithmatic progression = Speed Spindle Successive Upper limit of Range of diameter Remark step speed (n) speed ratio diameter (D,) in (8D,) in mm @ inom (6) mm = r 1 60 1.687 132.6291 53.0517 ___—_—~Poor for : low 2 100 14 79.5774 22.7363 _— spindle ‘speed 3 140 1.2867 56.8411 12.6314 range 4 180 1.222 44,2097 8.0382, 5 220 1.1818 36.1715 5.5648 6 260 1.1538 30,6067 4.0809 7 300 1.133 26.5258 3.1207 8 340 1.1176 23,4051 2.4637 L8 380 4.1052 20.9414 1.9944 1-9 Mechanical System DesignDesign of Machine Too! Gearbox 1.8476 ! 10 420 1.0952 it 460 1.0869, 1.384 12 500 : * From the above Table 1.1 it is clear that, for arithmatic progression, at low spindle speeds the diameter range is very wide and it is required to add more speed steps between the calculated values. * Similarly, at high spindle speeds the diameter range is very narrow and it is observed that some of the speed steps are redundant. ¢ It means, multi-speed drive with arithmatic Progression is poor in low spindle speed range. 2. Speed steps based on Harmonic Progression * In this law of progression, the difference between the reciprocal of any two successive spindle speeds is constant. ° Let, max and Min = Maximum and minimum spindle speed in rpm Ny, M2....m, = Different spindle speeds in rpm Z = Total number of steps * The difference between the reciprocal of any two successive spindle speeds is, 1 1 — a eeeeeSsSsSsSC‘ - = Constant C s+ (6) Mk AkeT oa MKT nk 1 Oke NK 4 , Muay = int (LI) Mer - or tm 7 iSGag ~@ © The ratio of successive spindle speeds is, = Bett 1 con (4 = Rima -». [From equation (i)) or Neat = OK My o (18) 1-10 Mechanical System Design——E—————————————— Design of Machine Tool Gearbox © The range of diameters for any speed step is, BD, = Dy -Dyat a, = --Y -¥(1- 1) Tn Ms AM Akay v ‘ aD, = =xC [From equation (1.6)] SD, = Constant -- (1.9) © The different spindle sneeds are, ny = Omin my 5 "en [From equation (1.7)] Similarly, © For example : Consider a multi-speed drive having following specifications = Maximum spindle speed (max) = 500 rpm Minimum spindle speed (yin) = 60 rpm Number of speed steps (z) = 12 Cutting speed (V) = 25 m/min 1-11 Mechanical System DesignDesign of Machine Tool Gearbox For the above data, the different Parameters based on harmonic progression are calculated as follows : ¥) Spindle speeds : We know that, Dmax = 00 = 9 st (12-1) Cx60 1-woc = & ” C = 1333x1073 Ninin = 60 rpm 60 5 —— = 65.2159 2 1333x107 x60 ™= ny 60 ny = ot a 8 959 en 9 1=2Cny ~ 1=2x1.333x 103 x60 he ny 60 ics = 9 __ pg 9411 4 ©" 1-3Cny ~ 1-3x1.333x10 x00 m 60 h 5 = 88.2249 5 1-4x1.333x 109 x60 " ny 60. ng = ot og gg 6“ 1-5Cny ~ 1=5%1.333x103 x60 7m ny 60 ny = ote is 35g 7" 16CHy ~ 1=6x1.333x107 x60 = ay 60 a ———" ___ = 136 3202 8 Cny 1-7%1.333x10"3 x60 _ ny 60 rye =——_—" __ = 166.5926 rpm ° 8Cn) 1-8x1.333x107 x60 ” 1-12 Mechanical System DesignDesign of Machine Tool Gearbox ny 60 rn ——___—__.——_ = 214.148 rpm 0 =9Cm 9x 1,333 x10 x60 ™ ny 60 mn — = SS = 299.7003 rpm a -10Cn, — 1-10x1.333x103 x60 » 0 i 590 111.333 107 x 60 ae ny = ii) Successive speed ratio : ra he Ee 1.0869 ae Boo Baise 7 1982 ie Bo = Trapsg 7 1082 ae Bear” LS 65 = Bi mT 1.1332 c= Feo Fema 7 13075 &- a ee 7 LISI ae ao iSesoms 7 122 = Se eas 1.2854 toe qe ae 1.3995 oe De i 1.6683 iii) Upper limit of diameter of workpiece : 7957.747 —— mm nk 1-43 ‘Mechanical System DesignDesign of Machine Tool Gearbox D, = 7957.747 = 1997.747 © 132.6291 mm my 60 T9ST.T47 _ T9S7.747 _ Da = Ty esis 7 1220215 mm _ 1957-747 _ 7957.747 _ Da = = argggy 7 14137 mm 7957.74 ‘957.747 Da = DS = ae pary = 100.8061 mm 7957.747 _ 7957.747 _ Ds = = Fgzap 7 90.1984 mm _ 1957.747 _ 7957.747 _ De = = Sogggg 7 79.5907 mm p, = 252-747 _ n7 7957.747 _ 7957.747 _ Ds = = igeapgg 7 583754 mm 7957.747 _ 7957.747 Dy = rr 166.5926 ~ 47.7677 mm 7957.747 _ 1957.747 _ Dio = To ya ag ~ 37-16 mm _ I9ST.T4T _7957.747 Dur = a= 300-7003 ~ 26:5523 mm _ 7957.74 _ 7957.47 _ Diz = a Sg = 15.9154 mm iv) Range of diameters : SDq = (Dy ~Dy+1) mm 8D). = D, — Dz = 132.6291—122.0215 = 10.6076 mm §Dz = D2 —D3 = 122.0215-111.4137 = 10.6078 mm 8D; = D3; —D4 = 111.4137 100.8061 = 10.6076 mm 8D4 = D4 —Ds =100.8061-90.1984 = 10.6077 mm 8D = Ds —Dg = 90.1984 79.5907 = 10.6077 mm 1-14 Mechanical System Design ccDesign of Machine Too! Gearbox 0.6076 mm 8D6 = Dg —Dz = 79.5907 — 68.9831 = 8D, 7 —Dg = 68.9831 — 58.3754 = 10.6077 mm SDg = Dg —Dg = 58.3754- 47.7677 = 10.6077 mm 8Dg = Dg —Dio = 47.7677 — 37.16 = 10.6077 mm BDyp = Dy —Dy, = 37.16-26.5523 = 10.6077 mm 8D, = Dy) —Dy2 = 26.5523 - 15.9154 = 10.6369 mm vi) Parameter summary : © All of the above calculated parameters are summarised in the following Table 1.2 Table 1.2 : Range of diameters for different spindle speeds in harmonic progression Speed Spindle Successive Upper iimit of Range of Remark Step (z) speed (n) speed ratio diameter (D,) in diameter (D,) in in rpm (9) mm mm 1 60 4.0869 132.6291 10.6076 2 65.2159 1.0952 422.0215 10.6078 3 71.4252 1.1052 411.4137 10.6076 L4 78.9411 4.1178 100.8061 10.6077 _ 5 88.2249 1.1332 90.1984 40.6077 6 99.9833 4.3075 79.5907 10.6076 i ez 115.3579 1.1817 68.9831 10.6077 [z 8 136.3202 1.2224 58.3754 10.6077 9 166.5926 1.2854 47.7677 10.6077 fa bo! 10 214.148 1.3995 37.16 10.6077 spindle speed range 14__ 299.7003 1.6683 26.5523 10.6369 12 500 15.9154 © From the above Table 1.2 it is clear that, for harmonic progression, the range of diameters is constant throughout. But, the speed steps are too wide at high spindle speeds. © It means, multi-speed drive with harmonic progression is poor in high spindle | speed range. 1-15 Mechanical System Design——— hr Design of Machine Tool Gearbox 3. Speed steps based on geometric progression © In this law of progression, the ratio of any two successive spindle speeds is constant. This ratio is called as geometric progression ratio. © Let, Amax 24 Myyjn = Maximum and minimum spindle speed in rpm ny, np....n, = Different spindle speed in rpm z = Total number of speed steps = Geomerric progression ratio (constant) or @ = MeL wa(1.10) nk * Now, Dmax _ min Mma _ Dinin Bmax Dmin Dax _ Rinin or ee (HD) where, R, = © The different spindle speeds are, By = Dinin nz = 0y°O= Min? ny = 2°= Mypin “97 1g = 13-O=Apin nz = MG) O=M | i 7-16 Mechanical System Design | dsDesign of Machine Tool Gearbox © For maximum cutting speed 'V' under the particular machining condition, the diameter range of workpiece that can be machined at a particular speed 'n,' is, Upper limit of diameter ie. D, = —Y— Ty " 7 ‘ Vv Lower limit of diameter ie. Dy4; = TNs Range of diameters is, BDy = Dy -Dyst sp, = YY -¥f4 ao Kan AM LM Oke ae © For example : Consider a multi-speed drive having following specifications : Maximum spindle speed (max) = 500 rpm Minimum spindle speed (min) = 60 rpm 12 Number of speed steps (2) Cutting speed (V) = 25 m/min For the above data, the different parameters based on the geometric progression are calculated as follows : i) Geometric progression ratio : 1 _ 3007] 121 ¥ -[3] % ii) Spindle speeds : Dy = Mypin = 60 rpm ny = ny- = 60% 1.2125 = 72.75 rpm ng = ny-6? = 60x (1.2125)? = 88.2093 rpm ng = ny-93 = 60x (1.2125)? = 106.9538 rpm ns = n,-64 = 60x(1.2125)* = 129.6815 rpm ng = ny +65 = 60x (1.2125)> = 157.2388 rpm 1-17 Mechanical System Design tDesign of Machine Tool Gearbox ny = n+ = 60% (1.2125)° = 190.6521 rpm ng = ny-67 = 60x(1.2125)? = 231.1657 rpm ng = ny-$8 = 60x (1.2125)* = 280.2884 rpm Ayo = yO = 60x (1.2125)? = 339.8497 rpm nyy = ny, -! = 60x (1.2125)'° = 412.0678 rpm ny = ny-o!! = 60x(1.2125)!! = 500 rpm iii) Upper limit of diameter of workpiece : V__ 25 _ 7.9577 7957.47 m=———— mm OK am am oh” mh” p, = 2957-747 _ 7957-747 «139.6991 mm ny 60 7957.747 _ 7957.747 Dy = = Oye 7 109.3848 mm 7957.747 _ 7957.747 Ds = 3 = ggzggg = 902143 mm 7957.747 _ 7957.747 Dy = EN a Toegaag 7 744035 mm 7957.747 _ 7957.747 Ds = SONIA _ Deel = 61.3637 mm 7957.747 Dy - Jey aiey ~ 50-6093 mm 1957.747 _ 7957.747 D7 one 7 ny 190.6521 ~ 41-7396 mm 7 Dg = 82747 _ 7957-747 _ 54 4944 mm 7957.747 Dy = 0.2884. ; oH oagga = 283912 mm De = = 23.4154 mm 1-18 Mechanical System DesignDesign of Machine Tool Gearbox 7957.747 dp, = SS W 7957.747 Dr = n 2 iv) Range of diameters : SDq = (Dy -Dys1) mm 8D, = Dy —Dz = 132.6291 - 109.3848 = 23.2443 mm 3D) = Dz —D3 = 109.3848—90.2143 = 19.1705 mm 8D3 = D3 —Dg = 90.2143— 74.4035 = 15.8108 mm 8D,4 = D4 —Ds = 74.4035 -61.3637 = 13.0398 mm Ds = Ds —Dg = 61.3637 — 50.6093 = 10.7544 mm 8D, Dz = 50.6093 ~ 41.7396 = 8.8697 mm 8D7 = Dy —Dg = 41.7396—34.4244 = 7.3152 mm Dg = Dg —Do = 34.4244 28,3912 = 6.0332 mm Do = Do —Dyo = 28.3912-23.4154 = 4.9758 mm BDyq = Dyo —Dyy = 23.4154—-19.3117 = 4.1037 mm Dy) = Dy, —Dyp = 19.3117 -15.9154 = 3. 3963 mm " vi) Parameter summary : * All of the above calculated parameters are summarised in the following Table 1.3 : Table 1.3 : Range of diameters for different spindle speeds in geometric progression Speed Spindle Geometric Upper limit of Range ‘step (z) speed (n) omen diameter (Dy) In diameter (30x) 1 60 1.2125 132.6291 23.2443 Poor for tow spindie| 2 3 88.2093 1.2125 90.2143 15.8108 ee 4 106.9538 1.2125, 74.4035 13.0398 1-19 Mechanical System DesignDesign of Machine Too! Gearbox 5 129.6815 1.2125 61.3637 10.7544 6 157.2388 1.2125 50.6093 8.8697 po 190.6521 1.2125 41.7396 7.3152 8 231.1657 1.2125 34.4244 6.0332 9 280.2884 1.2125 28.3912 4.9758 10 339.8497 1.2125 23.4154 4.1037 11 412.0678 1.2125 19.3117 3.3963 12 500 15.9154 * From the above Table 1.3 it is clear that, for geometric progression, at low spindle speeds the diameter range is very wide and it is required to add more speed steps between the calculated values. Similarly, at high spindle speeds the diameter range is very narrow and it is observed that some of the speed steps are redundant. ¢ But from Table 1.1 and 1.3 it is observed that, the variation in diameter for geometric progression is not as much as for arithmatic progression. ¢ It means, multi-speed drive with geometric progression is poor in low spindle speed range. 1.3.2 Comparison of Different Progression in Gearbox Design 5 [ SPPU : Dec. 2014, May 2015 ] The comparison of arithmatic, harmonic and geometric progressions is as follows : Sr. No. Arithmatic Progression Harmonic Progression _ Geometric Progression (AP) (HP) ( (GP) 1. In case of AP, there is _In-case of HP, there is. In case of GP, there is constant change in speed constant diameter change constant gear ratio at at every stage. at every stage. every stage. 2. AP is not based on HP is not based on GP is based.on preferred Preferred number of series. preferred number of series. number of series. 3. In this case, low speed In this case, high speed For GP, low speed range Tange requires more steps range requires more steps _is better than AP but still for optimised machining. for optimised machining. _ requires few more steps for optimised machining. 1-20 Mechanical System DesignDesign of Machine Tool Gearbox For AP, Dmax ~Smin Seed y= M21 +2 = Min +(2-1) ag For GP, 1 _ (max +-(ra) m= Meo = Amin Dy From the above table it is clear that, AP is inefficient in low speed range whereas HP is inefficient in high speed range. To overcome the drawback of both progressions, geometric progression (GP) is used. 1.3.3 Advantages of Geometric Progression ss [ SPPU : Dec. 2012, May 2014] » From the previous article it was clear that, the geometric progression is suitable cover the arithmatic and harmonic progression. The other advantages of geometric progression are as follows : @ Constant loss of economic cutting speed in total speed range Let, ny and ny, = Intermediate spindle speeds in rpm Vy, and Vj4, = Cutting speeds for two spindle speeds in m/min Dy, and Dy41 = Diameter of workpiece for corresponding cutting speed in mm Vopt = Optimum cutting speed in m/min Nopt = Optimum spindle speed in rpm During the operation, the operator will set one of the spindle speeds ny or ny depending upon the speed which is closer to the nog for machining a particular diameter. Let, optimum spindle speed nop lies between the two spindle _ speeds ny and ny4; as shown in Fig. 1.2. For any case, the net difference between the actual cutting speed and the optimum cutting speed is, €1 = Verr~ Von @ ©) = Von Vk = Gi) 4 Pet Veet Cutting speed (in/min) —» D Diameter (mm) —= Fig. 1.2 : Relationship of cutting speeds and work-piece diameter 1-21 I System DesigrDesign of Machine Tool Gearbox nDny where, Ve = T000- = nD ost Viet - 1000 and Vi < Vope < Vis ° The difference between the actual cutting speed and optimum cutting speed [Equation (i) or (ii)] is called as loss of economic cutting speed. + If € [ SPPU : May 2013 ] © To obtain a balance between the loss of economic cutting speed and the number of speed steps, the value of 6 is selected between 1 and 2. © The standard values of '' are based on the preferred number of series. The values are as follows : Table 1.4 : Standard values of geometric progression ratio (¢) Sr. Preferred series Geometric progression ratio (4) tuo = 910 = 1.06 20 = 7990 = 1.42 R10 Q “$10 = 1910 = 1.26 R (20/3) Lee 9, 410 = 1.41 a 5 RS 5 = {10 = 1.58 R4 gg = M0 = 1.78 7 R (10/3) : ait tig, = Vi = 2.00 ‘© The recommended values of geometric progression ratio ($) and corresponding effect on loss of economic cutting speed and number of speed steps is shown in Fig. 1.4. © The standard spindle speeds for different preferred series of geometric progression ratio are given in Table 1.5. * Consider a speed range from 10 rpm to 1000 rpm. The values are rounded off for convenience. 1-25 Mechanical System DesignSpeed steps, z % Emax Design of Machine Tool Gearbox srry aa0 SS 2 tor r= t0 0 11.06 1.12 1.26 Heavy dt chine) f tool and automate 2.00 GP ratio, ¢ Medium to small sized general purpose machine tools Fig. 1.4 : Plot of 6 versus 7, % Cmax * The values are obtained by multiplying the preceeding value by $ . For example : For R 40 series [Refer Table 1.5], 10x1.06 = 10.6, 10.61.06 = 11.236 ~11.2, 11.21.06 = 11.872=11.8 For R 20 series, 1Ox1.12 = 11.2, 11.2%1.12 = 12,544 ~12.5, 12.51.12 = 14 2 soon Table 1.5 : Standard spindle speeds for various values of '¢' $ |@40 = 1.06 429 = 1.12] 49 = 1.26] $20/3 = 1.41] 5 = 1.58 | $4 = 1.78 |r = 2.0 Spindle | _10.0 10.0 10.6 10.0 1 10.0 10.0 10.0 10.0 1-26 Mechanical System DesignDesign of i ine Tool Gearbox 6 [eao = 1.06] G29 = 4.42] 40 = 1.26] 20/3 = 1.41] Os = 1.58 | ¢. = 1.78 [O1a/9 = 2.0 Spindle} 11.2 112 a 11.8 125 12.5 12.5 13.2 L 14.0 14.0 140 15.0 16.0 16.0 16.0 16.0 17.0 180 | 160 18.0 19.0 | 20.0 20.0 20.0 20.0 20.0 21.2 | 224 le 22.4 - 1 25.0 25.0 25.0 25.0 26.5 28.0 28.0 28.0 30.0 31.5 31.5 31.5 315 33.5 35.5 35.0 37.5 E wo | 40.0 40.0 40.0 40.0 40.0 42.5 a Lo 1-27 Mechanical “yj: DosignDesign of Machine Tool Gearbox si $ _|40 = 1.08] 29 = 1.12] b10 = 1.26] daoy3 = 1.44 [os = 1.58 | 64 = 1.78 loos = 2.0 Spindle] 50.0 50.0 50.0 Speeds, rpm, 53.0 56.0 | 560 56.0 [| 560 [ 60.0 212 |Design of Machine Tool Gearbox 6 [640 = 4.06] 629 = 1.12] O10 = 1.26 | O2oy3 = 1.41 Os = 1.58 | 04 = 1.78 [10/3 = 20 Spindie| 224 224 224 — "| 236 c 250 250 250 250 265 45.0 280 280 300 315 316 315 315 T 315 315 1000 1000 | ‘Mechanical System DesignDesign of Machine Tool Gearbox 1.4.2 Geometric Progression Ratio ($) for Drive with Two Speed Motors © In various machine tool drives, the input speeds are varied by using two motors. The speed ratio of these two motors is generally 2 (3000 rpm and 1500 rpm or 1440 rpm and 720 rpm). © As the spindle rpm values are in GP for the lower rpm motor, the speeds should increase to two times when the input speeds are increased to the higher rpm motor. * In order to satisfy this condition, any spindle speed ny must double after certain number of speed steps 'S;'. ny oSl = 2ny oS = 2 or o= {si} = @ © But, the value of should be based on preferred series, Let, 'S,' be the any preferred series. Therefore, 1 6 = Y0=(10) .. Gi) Equating equations (i) and (ii), 1 1 _ @* = ao) 1 . g, e810) = = Preferred series number such as 40, 20, 10, etc. * From the above equation (1.14), the standard geometric progression ratio $ for drive with two speed motors can be obtained. The values are tabulated as follows : 1-30 Mechanical System Design————— Design of Machine Tool Gearbox ‘Table 1.6 : Standard values of with S; and Sy 8 1 12 15 2 3 6 12 10, 29 S2 , 4 5 M%, 10 20 40 Prefered R1 R4 R5 R20, R10 R20 R40 pe % 6 2.00 1.78 1.58 141 1.26 1.12 1.08 4.5 Parameters in Kinematic Design of Multispeed Gearbox 5 [ SPPU : May 2013 ] « The parameters to be considered in kinematic design of multi-speed gearbox are as follows : () Maximum spindle speed (max) (ii) Minimum spindle speed (1 yyin ) (iii) Number of spindle speed steps (z) (iv) Number of transmission stages of (v) Electric motor speed (Nem ) gearbox (N) @ Maximum and minimum spindle speed (max 204M min ) The maximum and minimum required spindle speeds can be obtained by knowing the minimum and maximum diameter of the workpiece to be machined and corresponding maximum and minimum cutting speed. © The maximum and minimum spindle speeds are given by, 1000 Vinax Mmex = po? TPM TD min 1000 V spi and Main = Se apm = Maximum and minimum cutting speed in m/min. = Maximum and minimum diameter of workpiece to be Where, Vinax and Vipin Dax 204 Dimin machined in mm. (i) Number of spindle speed steps (z) As it is already discussed that, range ratio for a multi-speed gearbox is, _ max _ (1000 V Amin (1000 Vinin / Dax) 41-31 Mechanical System Designwhere, Ry = ¥ Design of Machine Tool Gearbox RyxR vu (1.15) v D min = Range of cutting speeds employed on machine tool. D Rp = 5™* = Range of workpiece diameters to be machined. min The value of R, should be within the permissible limit. The higher value of R, results in loss of productivity. The value of Ry can be obtained by considering the economics of machining (maximum production rate and least unit cost). . The value of Ry is between 2 (for special purpose machines) to 6 (for general purpose machines). Based on the value of Ry and Rp, the value of R, can be determined. The value of R, can be further increased by 20 to 25 % of the machine tool uses newer technologies for machining. The different values of Rj for different machine tools are given in the following Table 1.7. Table 1.7 : Range ratio for different machine tools Type of machine tool Range ratio R, Center lathe and boring machines 40 - 60 ‘Milling machine 30 - 50 ‘We know that, Ry = oe logio Rn = (2-1) logio > .. (Taking log on both sides) 1-32 Mechanical System Design—————E—————————————_———— Design of Machine Tool Gearbox logio Rn logio ¢ I R 7 = 80 Ray logio ¢ logio Rn + logio _ logi0 (Rn 4) logio & logio (4) © The above cquation (1.16) is used to find the number of speed steps for a given value of Ry, and 9. If the obtained value from the above equation is not a whole number then it is rounded off to the nearest whole number which can be split into the multiple of 2 and 3. «The following Table 1.8 shows rounded and preferred values of z : Table 1.8 : Rounded and preferred values of z z-1= z= w (1.16) Spindle speed steps z__ Rounded or split value 6 ek as a 8 5 2nd © 9 3x3 [ 12 2x2x3_ I 16 © 2x 2x2x2 . The norenly,ecierieg values Of 2:2 4, 6, 8, 9, 12, 16, 18, 24, 27, 32, 36, qu Naber of transmission stages of gearbox (N) © The number of transmission stages or groups of a multi-speed gearbox is given by, z= 2N.3N2 oI) Where, N, = Number of stages having two speed steps N2 = Number of stages having three speed steps N = Total number of stages in a transmission group = N|+Np * The following Table 1.9 gives the number of two speed steps and three speed steps for the standard values of z and corresponding total number of stages: 1-33 Mechanical System DesignDesign of Machine Tool Gearbox Table 1.9 : Number of stages for standard values of z z 2M x 3N2 Ny Ny Ny+N2 = N 2 2x3? 1 0 14+0=1 4 2x 90 2 0 2+0=2 6 23! 1 4 1+15 8 2x30 3 0 é 9 20x 3? 0 2 12 2x3! 2 1 16 2 x30 wie 0 18 2x3? 1 2 : 2x3! 3 1 29x38 0 3.8 25x30 5 0 2 2 2 © The total number of spindle speed steps is given by, ‘Number of speed ) (wee of speed ) steps in first stage, steps in second stage « Let, P, = Number of speed steps in first stage (group) P, = Number of speed steps in second stage (group) ‘Number of speed steps in last stage, Py = Number of speed steps in N' stage (group) «It means, for the total number of spindle speed steps, Z = PLP Xeeseeeee XP © To obtain the required speed steps 'z' by using minimum number of gears, it is necessary that all stages should have the same number of speed steps. P, = Py = Py =P Z = PL XPy XeeseenX Py =PXPX 1 fe P= (@N a (1.18) Mechanical System DesignDesign of Machine Tool Gearbox (iv) Electric motor speed (em) ‘© The speed of electric motor is required to decide the speed of input shaft of the gearbox and the mode of transmission from motor shaft to input shaft. If the speed of input shaft of gearbox and motor shaft is same then they are directly coupled. But, if there speeds are different then use either belt drive or gear drive to connect them. 4.6 Kinematic Diagram of Gearbox (Gearing Diagram) * After deciding the range ratio, geometric progression ratio, the number of speed steps and the number of transmission groups, it is necessary to construct the kinematic diagram or gearing diagram of the gearbox. © This would include determine the following : © To determine the number of shafts in gearbox © To determine the number of gears on each shaft. © To determine the layout of arrangement of the gears. © To determine the number of teeth on each gear. © For constructing the kinematic diagram of the gearbox, it is required to know the distribution of speeds on input shaft, intermediate shafts and output shaft. For this purpose the following parameters are important : ( i) Structure formulae ii) Structure diagram iii) Ray diagrams and speed diagrams 1.7 Structural Formulae sar [ SPPU : Dec. 2013] _ © Structural formula is the mathematical expression giving the number of speed steps in each stage and the number of spindle speed steps by which two adjacent speed values of each stage are separated. * As it is already discussed that, multiple speeds can be obtained by, Z = Py XPy XP 3X cessesene XPN, ‘In some cases, it is not possible to have equal values of P. For example, consider a case where there are three transmission stages (groups). Hence the above equation becomes, z= P)XP)xP3 This relation can be written in the following ways : z = P, xP, xP3 =P) xP; xPp = P) xP, xP; =P, XP; XPy = P3 xP2 xP) = P3 XP; XP> 1-35 Mechanical System Design meneeensessereereDesign of Machine Tool Gearbox * The vaiue of z can be obtained by any of the above six combinations. If there are N such stages, the number of combinations would be factorial of N (N!). © If any of the above have an equal number of speed steps, then the number of combinations will reduce. For example, consider a case when P, =P3 (there are two stages where the transmission is equal ite. q = 2). Where, q = Number of stages where transmissions are equal © In this case, the number of combinations will be, Z = P, xP) xP3 =P) xP) xP, ~ (P, =P3) = P) xP, xP, =P) xP xP, It means, in this case only three combinations are possible. For this case, the number of combinations can be found by using the following equation, Ni _3! qe 2! * We now consider the case where we analyse the difference between two adjacent speeds ‘x’ in a given stage (where, x is the characteristic of that transmission stage). © For a given transmission group, if the difference between two adjacent speed values is 1 then x = 1 and if the difference between two adjacent speed values is 2 then x = 2. * Now a more elaborate expression for total number of spindle speeds can be written as, 3 Number of distinct combinations Z = Py(x1) Po(x2) ~ Puy) we (1.19) The above equation is called as structural formula for multi-speed gearbox. * As discussed earlier, the number of speed steps can be arranged by N! terms. By Tearranging —X1,X2y-0.0)Xy We can obtain N! combinations of, X]pX2yecneevey Xpy for the same combination of P,, Pz, .-.eus; Py- + Therefore, a multi-stage gearbox with N stages can have a total (N!)° structural arrangements and corresponding different kinematic arrangements. © The values of x}, x, x3,. x, = 1 x2 = Py x3 = PixP, Xy = P)XP) x For example : Consider a 12 speed gearbox (z = 12) Z = 12 = 2N1x3N2 = 22x3! 1-36 Mechanical System Design—————————————————————— Design of Machine Too! Gearbox N =Ny+Ny = 24+1=3 z = 2x3x2 or 2x2x3 or 3x2x2 ‘The number of stages where the transmissions are equal, q = 2 3! N! Number of distinct combinations = a But, the gearbox have three stages and would have only three possible combinations (as Pp =P3). Each stage can also have three different characteristic. Thus the total number of combinations would be, = Number of distinct combinations x 3! = 3x3!= 18 Note: If P,, Pyand Py are three distinct values then the number of combinations would be, =31x31=())? = 36 « For this case, 18 possible structural equations are tabulated as follows : Table 1.10 : Possible structural equations for 3 stage, 12 speed gearbox Sr. Py Po P3 xq 4x2=P) x3 =X2 Pj Combinations No. 2 ee 2 0 1 2(P1) = 2x3(P, Pe) 2=PiOa) Pole) Pals) = 6(P; Po) = 21) 2(2) 26) = 12 @ 1 2(P)) = 2x2 Pa) Z= Pil) Polxs) Palxe) =4(P,/P3) = 2(1) 3(4) 2(2) = 12 [ 1 3(P2) = 3x2 (Pz) Z= Pix) Pola) Palka) =6 (PP) = 2(3) 3(1) 26) = 12 ™ 1 3(P2) = 3x2 (P_ Pa) 2 =Pilxs) Pale) Pala) = 6 (Pr Ps) = 26) 3(1) 23) = 12 [ 1 2(Ps) = 2x2 (Ps i) (x2) Paka) Pal) = 403 P) = 2(2) 3(4) 21) = 12 1-37 Mechanical System Design(en TEST SE Design of Machine Tool Gearbox wi 1 2(Pa) = 2x3(Py Pp) z= Prlxg) Polka) Py(xy) = 6 (P3 Pp) = 26) 3(2) 21) = 12 4 3 per 2 0 18) = 3x2 (P,P) Z= Px) Polke) Pylxg) = 6 (P; Po) = 3(1) 2(3) 2(6) = 12 @) 1301) = 3x2(P, Py) z= Play) Polka) Palxa) = 6 (P, Py) = (1) 26) 23) = 12 ) 1 2 (Po) = 2x3 (PoP) z= Pyixe) PolK) Py(xg) = 6 (P: Pr) = 32) 2(1) 26) = 12 | (iv) 1 2(P2) = 2x2 (Pp Ps) Z=PiX3) Po(x1) P32) L = 4 (Po Ps) = 3(4) 2(1) 2(2) = 12 ) 1 2 (Pa) = 2x3(PyP)) z= Pra) Poly) Pa(xs) = 6 (PsP) = 3(2) 26) (1) = 12 (vi) 1 2 (Ps) = 2x2 (Py Pe) z= Pixs) Pala) Pa(xs) = 4 (Ps Po) = 34) 22) 21) = 12 22s 8 @ 1 20) = 2x20, P:) z= Pox) Pabxz) Paina) 1 =4(P Pe) = 21) 22) 3(4) = 12 | (i) 121) = 2x3(P, Py) z= Pyxy) Polxs) Palo) =6(P, P3) = 2(1) 2(6) 3(2) = 12 Gi) 1 22) = 2x2 (PrP) z= Pina) Pe(%4) Pa(xs) = 6 (P2 Pi) = 22) 21) 3(4) = 12 ww 1 2 (Pe) = 2x3.(Pp Ps) 2 = Pix) Pylx) Py(x2) = 6 (P,P) = 2(6) 2(1) 3(2) = 12 | 0) 1 34Pa) = 3x2 (PP1) Z2= Prix) Pylxs) PalKy) = 6(P3 P,) = 2(3) 2(6) 3(1) = 12 (wi) 13a) = 3x2 (Py Pe) z= Pylxa) Pole) Pylxi) = 6 (Ps Pp) = 2(6) 2(3) 3(1) = 12 1-38 Mechanical System DesignVE ee ee Note = Design of Machine Tool Gearbox From the above different structural formula obtained, the following condition should always be fulfilled to have feasible kinematic solution : @ ae must be an integer number greater than or equal to 1. (i) Product of P xx must be less than or equal to z. 1.8 Structure Diagram «© These The structural formulae, which describe the kinematic structure of the gearbox are represented in the form of special graphs called as structure diagrams. diagrams are also called as Germer layouts after the name of R. Germer who invented them. + For example : Consider a 4 speed gearbox (z = 4). It means, Also, =2N1 x3N2 = 2? x3? N = Nij+N, =2+0=2 z= 2x2 Pi = P)=2 x, = 1 and x, =P, For this case there are two possible structural equations [Refer Fig. 1.5], z=2(1) 2(2)=4 or Z=2(2) 2(1)=4 @ 2=2(1) 22) Itindicates there are 2 outputs It indicates with spacing of 1 there are 2 outputs with spacing of 2 i) z= 202) 2(1) It indicates there are 2 outputs _It indicates with spacing of 2 there are 2 outputs with spacing of 1 1-39 Mechanical System Designre rm Design of Machine Tool Gearbox T a m [ist] [iteguadie) foxes shaft. shaft shaft 2. bE i | i 202 i Stage 1 Stage 2 | (a) 2(1) 2(2) T I m (scd]_ Pace] [ee] 2 k a af “8 2 We XY 20) 2) ! ‘Stage 1 ‘Stage 2 (©) 2(2) 2(1) Fig. 1.5 : Concept of structure diagram 1.8.1 Procedure for Constructing Structure Diagram * The following procedure is used to construct a structure diagram for a gearbox having ‘N' number of stages and 'z' number of spindle speeds : @ Draw (N+1) number of vertical lines at a suitable distance from each other. The first vertical line represents the input shaft, whereas the last vertical line Tepresents the output shaft. The remaining vertical lines represents the intermediate shafts which form a transmission group or stage of the gearbox. Gi) Draw 'z' number of horizontal lines at an internal of logy ¢. Each horizontal. line represents a spindle speed. The reason for equal distance between the horizontal lines is as follows : Let, nj = Minimum spindle speed in rpm 1-40 Mechanical System Design |Design of Machine Tool Gearbox As per geometric progression ratio, ny > or Logio (2) = logio (m1) + logio ¢ ny = m2 or —logio(n3) = logio(nz)+ logig ¢ n, nz =Mz4 6 or —logio(nz) = logio(nz-1)+ logio > It means, the interval between each horizontal line would be logig >. (iii) Using the structural formula, Z = Py(X4) Pa(Kp) P33) oeenenee PyCKN) Plot the values of P;(x,), Po(xz), P3(x3), etc. Refer Fig. 1.5. 1.8.2 Features of Structure Diagram . By drawing the structure diagram the designer can imagine the flow of transmission in the gearbox and it provides the following features : © The number of shafts in the gearbox. © The number of gears on each shaft. © The order of changing transmissions at each stage to get the required spindle speed. © The transmission range and the characteristic of each transmission group. Fig. 1.6 (a) shows the kinematic arrangement of a four speed gearbox based on the structure diagram shown in Fig. 1.5 (a) and (b). Fig. 1.6 (a) Arrangement for a 4 speed gearbox 1-44 Mechanical System DesignOE Design of Machine Tool Gearbox * Both the structures have the same kind of arrangement but the sizes of gears are different because their transmission ranges are different. * The possible arrangement of gears which provides the required 4 speeds is shown in Fig. 1.6 (b). Fig. 1.6 () Flow of transmission to get the 4 speeds * The gears with marking of two-way arrow (<>) are sliding gears and the remaining gears are non-sliding type (fixed on the shaft). + It is important to note that, the gears shown by dotted lines rotate on the corresponding shaft but they are not engaged with any other gear for transmission of power or motion. 1.8.3 Laws of Structure Diagram The drawn structure diagram for a particular structural formula should satisfy the following laws : ° Each line must connect another follow-up line till the final output shaft is reached. Refer Fig. 1.7 (a). ¢ At any stage the arrow must end at one Point only (two arrows should not end at one point). But, at any input there can be more than one arrow (Generally, it is limited upto 3). Refer Fig. 1.7 (b). 1-42 Mechanical System DesigneS Design of Machine Too! Gearbox This point is I 0 not connected r zo . ae with an arrow i / Not connected \ ; Two arows by follow-up line ‘end at the ‘same point @ © pe Fig. 1.7 « None of the arrow should go beyond the boundaries of the speeds at the output shaft. Refer Fig. 1.7 (c). H shy This point is beyond the boundary Fig. 1.7 (©) © On the output shaft, all the points must be connected by the arrows. Refer Fig. 1.7 (b) , (c) and (e). © Arrows for a particular gearing must be drawn parallel when repeated for another set in the same stage. Refer Fig. 1.7 (d). * At output shaft, the arrows must terminate at the intersection and not in between the horizontal lines. But, at all other shafts arrows can start and end at the intermediate points. Refer Fig. 1.7 (e). 1-4 Mechanical System DesignDesign of Machine Tool Gearbox a Arrow ends in u between on the a ‘output shaft v ‘These points are not connected ) with an arrow le Point is not connected (@) with an arrow e) Fig. 1.7 1.8.4 Types of Structure Diagram ¢ The structure diagrams are of following two types : 1) Open type 2) Crossed type ) 1) Open type : If the structure diagram has no crossing lines then it is called as open type of structure diagram. Refer Fig. 1.8 (a). Parallel structures are not repeating I 0 m 1 0 m 1 0 m (a) Open type I 1 m 1 1 m 1 1 m + E “ (b) Crossed type Fig. 1.8 : Types of structure diagrams Mechanical System Designa Design of Machine Tool Gearbox 2) Crossed type : If the structure diagram has lines crossing each other then it is called as crossed type structure diagram. Refer Fig. 1.8 (b). 4.9 Selection of Optimum Structure Diagram u3° | SPPU : May 2013] ‘As discussed earlier, there are different possible structure formulae for a given range ratio and spindle speeds. Each structure formula give a different structure diagram which decides the kinematic design of a gearbox. © Hence, it is necessary to select the optimum structure diagram. «An optimum structure diagram is the diagram which results in a compact gearbox with minimum number of gears, shafts, levers and bearings. Based on certain rules optimum structure diagram is selected. These rules are listed as follows : 1) Restriction on transmission range 2) Minimum total shaft size 3) Minimum gears on output shaft 4) Maximum speed ratio in last stage 5) Maximum number of speed steps in any stage should not be more than three. 6) Input speed should be closer to motor speed 1) Restriction on transmission range © The transmission range (i,) of a group or stage is defined as the ratio of the maximum speed ratio to minimum speed ratio obtained in a stage. Mathematically, _ Maximum speed ratio obtained ina group _ imax ' ~ Minimum speed ratio obtained in a group © The maximum increase of speed is restricted to two times (2) due to limitations of the pitch line velocity, whereas the maximum reduction of speed is limited to (1/4) times to ensure that the radial dimensions of the gears are not very large. © It means, imax = 2 and iin -4 imax 2 s imin (1/4) Therefore, for optimum structure diagram, the transmission group in a gearbox should not exceed 8. s» (1.20) | Cig stage S 8 we (1.21) 1-45 Mechanical System DesignDesign of Machine Tool Gearbox 2) Minimum total shaft size * We know that, the power transmitted by the shaft is, 2nNT P= Watts oP _C ; or T= ENE 7 = @ where, C, = Constant As per torsional equation, T= Berne a wii) where, C2 = Constant Equating equations (i) and (ii), CL 3. g - 1 We a = oe pH 1)\3 or de (3) w= (1.22) © From the above equation (1.22), it is clear that shaft diameter is inversely Proportional to one third of the speed of rotation. * The torque is also inversely proportional to speed hence, lower the speed higher the torque has to be transmitted by the shaft and larger is the diameter of shaft. * For safe transmission of the torque, the gearbox shaft should be designed at minimum speed for the given stage. This ensures safe transmission of torque at all speeds. * In case of optimum structure diagram, the sum of diameters of all shafts should be minimum ie. (Ne) >.) = Minimum w= (1.23) 1 3) Minimum gears on output shaft The number of gears on the final output shaft should be as minimum as possible. 4) Maximum speed ratio in last stage (Group) © The speed ratio in the last stage or group should be as maximum as possible. For optimum structure diagram, Xp SX OX4< ceeee < XW 1-46 Mechanical System Design